Process for breaking petroleum emulsions



Patented Nov. 4, 1947 PROCESS FOR BREAKING PETROLEUM EMULSIONS Melvin De Groote, University City, and Bernhard Keiser,

Webster Groves, Mo.,

assignors to Petrolite Corporation, Ltd., Wilmington, DeL, a

corporation of Delaware No Drawing. Application April 2, 1945, Serial No. 586,266

Claims.

1 This invention relates primarily to the resolution of petroleum emulsions.

One object of our invention is to provide a novel process for resolving petroleum emulsions of the water-in-oil type, that are commonly referred to as cut oil, roily oil, emulsified oil, etc.. and which comprise fine droplets of naturally-occurring waters or brines dispersed in a more or less permanent state throughout the oil which constitutes the continuous phase of the emulsion.

Another object of our invention is to provide an economical and rapid process for separating emulsions which have been prepared under controlled conditions from mineral oil, such as crude oil and relatively soft waters or weak brines. Controlled emulsification and subsequent demulsification under theconditions just mentioned, are of significant value in removing impurities, particularly inorganic salts from pipeline oil.

Demulsification, as contemplated in the present application, includes the preventive step of commingling the demulsifier with the aqueous component which would or might subsequently become either phase of the emulsion in absence of such precautionary measures. Similarly, such demulsifier may be mixed with the hydrocarbon component.

The new material or composition of matter herein described consists of a hydrophile pyridinium compound of the formula:

Halogen in which R5 is a member of the class consisting of methylene and substituted methylene radicals representing the residue of low molal aldehydes; R is the radical obtained by the removal of an alpha hydrogen atom from the acid radical of a low molal carboxy acid ester of a phenoxyalkano] of the formula:

R (R20) nH in which R1 is a substituted monocyclic phenol radical having 2 of the 3 reactive 2, 4, 6 positions substitued by 2 alkyl side chains, of which at least one contains 3 carbon atoms and the longest of which does not contain more than 8 carbon atoms; R20 is an alkylene oxide radical containing at least 2 and not more than 4 carbon atoms and selected from the class consisting of ethylene oxide, propylene oxide, butylene oxide, glycide and methyl-glycide radicals; and n is a small whole number varying from 1 to 3, or even 4 or 5, or more, for instance, 6; R1 is the radical R10(R20)n'H with the proviso that 11. may vary from 0 to 3, or more, in a manner identical with the value of n. More specifically, the ester, derived from a compound in which a methylene bridge or the like unites the residues of 2 phenoxyalkanols, includes alkanol radicals in which the carbon atom chain is interrupted at least once by oxygen, i. e., etheralkanols or etheralcohols. Alternately, the methylene bridge may unite the residues of a phenoxyalkanol and the phenol, and thus, necessitating that the value of 11, include zero as well as 1, 2, or 3. As a matter of convenience, and especially for comparison with our co-pending application Serial No. 586,263, filed April 2, 1945, numerous illustrations will be concerned with the sub-genus, or where 2 phenoxyalkanol residues are present, and subsequently, there will be a more detailed consideration of the sub genus in which there is one phenoxyalkanol residue and one phenol residue.

The herein contemplated procedure involves steps which convert a water-insoluble chemical compound into a water-soluble compound by conversion into a pyridinium salt. In some instances, it may be necessary to use enough oxyalkylating agent that n or 12' may be as much as 6, instead of being limited to 3, in order to insure water solubility. Furthermore, it will subsequently be shown that one may conveniently react a diol of the kind contemplated as a reactant with one mole of a low molecular weight monocarboxy acid having '7 carbon atoms or less, such as acetic acid, butyric acid, propionic acid, or the like, and then subsequently oxyalkylate again prior to an esterfication with chloroacetic acid. Thus, it is to be recognized that R7 may not only represent the radical previously indicated, but may additionally represent R1O(R2O)11,OCR8 in which RBCO is the acyl radical of a monocarboxy acid having '7 carbon atoms or less.

In any event, the values of n and it must be such as to insure at least incipient hydrophile properties in the final product.

More specifically then, R in the first formula of the text represents the divalent radical by elimination of a nuclear hydrogen atom and a halogen from the ester of the formula:

R10(R20) nOOC.R3 Halogen in which all the symbols have their prior sig- 3 niflcance and OCRs halogen is the acyl radical of a low molal alpha chloromonocarboxy acid, such as chloroacetic acid. In other words, repeating the previous example with specific reference to chloroacetic acid, the formula becomes:

R10 (R20) nOOC.CH2C1 Briefly stated, the preparation of the herein contemplated compound consists in four steps:

reactions of this type are well known and do not require description. In the case of furfural it is desirable to use alkaline condensing agents, but in the other instances acid or acidic substances are usually employed. Since these condensation reactions cannot produce resins in. the usual sense, they are comparatively simple and result in oils varying from moderately viscous substances to oils so viscous as to appear to be almost solid.

The phenols are selected so that resinification does not take place, insofar that the phenols are limited to types in which there is only one reactive nuclear hydrogen atom. Specifically, then, the phenols may be indicated by the following formula:

Alkyl- Alkylwith the proviso that the 2 alkyl groups occupy 2 of the 2, 4, 6 positions, and that at least one of the alkyl side chains contains 3 carbon atoms, and-the longest alkyl side chain does not contain more than 8 carbon atoms. When 2 moles of such phenol are condensed in the customary manner with a reactive aldehyde, one obtains a substituted diphenylol methane, or substituted methane of the following formula:

in which R5 is a methyl radical, or a substituted methyl radical which represents the residue of an aldehyde and is preferably the unsubstituted methylene radical derived from formaldehyde.

As to various suitable phenols, we prefer to use 2-4-diamyl phenol or p-tert-butyl-o-cresol. Other suitable phenols include a- (3H2 C H- (Lethyl-propyl -ortho-cres 01 4 See U. S. Patent No. 2,073,995, dated March 16, 1937, to Raiziss et a1. See also U. S. Patent No. 2,106,760, dated February 1, 1938, to Raiziss et al.

Other phenols can be prepared by the alkylation of orthoor paracresol by the same procedure as is employed for the alkylation of phenol. See U. S. Patent No. 2,060,573, dated November 10, 1936, to Hester.

We have found that 2,4-dipropylphenol is also an excellent raw material. See also U. S. Patents $1 2,064,885, dated December 22, 1936, to Carpenter; #2,l04,412, dated January 4, 1938, to Buc, and #2,207,753, to Moyle et al., dated July 16, 1940.

It is understood that there is no objection to the presence of an addiitonal alkyl radical, provided its presence still leaves a reactive nuclear hydrogen atom. Such alkyl radical, if present, is limited to radicals having not over 8 carbon atoms and must occupy one of the 3 or 5 positions. For all practical purposes,'however, such compounds are derived from metacresol or similar homologues, and thus, for the sake of brevity in the hereto appended claims, such alkyl groups will be indicated as being in either the 3 position, or in the 5 position. For the sake of convenience, however, it is understood that the 3 and 5 positions are the obvious equivalents. One such example would be the product obtained by the propylation of metacresol. The meta group does not occupy a reactive position, and its presence does not interfere with the subsequent reaction. In a few instances, compounds are obtainable where a cyclic radical may serve instead of an alkyl radical, for example, in 4-tert-butyl- Z-phenylphenol or 4-tert-butyl-2-cyclohexylphenol.

Since the substituted phenols employed as reactants are invariably water-insoluble, and since formaldehyde, a water-soluble aldehyde, is the preferred reactant for introducing the methylene bridge or its equivalent, we have found it most desirable to employ the procedure described in U. S. Patent No. 2,330,217, dated September 28, 1943, to Hunn. Briefly stated, this procedure includes the use of an acid catalyst, along with an emulsifying agent to promote emulsification, and thus, reaction between the water-insoluble phenol and the water-soluble aldehyde, As an example of such procedure, the following is included:

PHENOL ALDEHYDE CONDENSATION Example 1 Pounds Diamyl (2,4) phenol 702 Formalin 40% U. S. P 114 Concentrated hydrochloric acid 3.3

Alkylated aryl sulphonic acid salt (Nac conal N, R. S. F.) 3.3

PHENOL ALDEHYDE CONDENSATION Example 2 The same procedure is employed as in the previous example, except that 618 pounds of dipro- 'nol and 309 pounds of dipropy1(2,4)phenol.

py1(2,4)phenol replaces the 702 pounds of diamylphenol used in the preceding example.

PHENOL ALDEHYDE CoNnENsArIoN Example 3 The same procedure is followed as in the two previous examples, except that one uses a mixture consisting of 351 pounds of diamyl(2,4)phe- The result of such mixture is that the condensate is also a mixture, of which one-third corresponds to Example 1, preceding, one-third to Example 2, preceding, and the remainin third represents the type of compound in which the phenol nuclei are different, one being an amylated nucleus, and the other apropylated nucleus.

Instead of using the emulsification procedure, one may, of course, employ another well known method, to wit, the use of an alkaline catalyst in excess, particularly in amounts suflicient to dissolve or solubilize the water-insoluble phenol. Usually, a sodium hydroxide solution is used to dissolve the substituted phenol. For complete details see, for example, Industrial and Engineering. Chemistry, volume 24, No. 4, page 442; volume 29, No. 8, page 860; and No. 11, pages 1125 and 1305. Particular attention is directed to volume 29, No. 8, page 862. The author of all these articles is F. S. Granger.

Due to ready availability, and other desirable properties, it is particularly convenient and economical to replace dipropyl(2,4)phenol with an equivalent amount of 4,6-di-tertiary-butyl-mcresol, which is indicated by the following formula:

In the second step of the method of producing our new material or compound, a properly selected phenol of the kind typified by the formula:

is treated with 2 to 12 moles of an oxyalkylating agent of the kind described, so as to produce a compound in which 2 phenoxyalkanols are united by a methylene bridge or substituted methylene bridge, as described. In any event, one must have incipient hydrophile property, as previously mentioned and described in detail subsequently.

If one employs 2 moles of ethylene oxide, the reaction may be indicated in the following manner:

Alkyl- 6 The third step of said method consists in esterifying the diol thus obtained with a suitable alpha-chloromonocarboxy acid, such as acetic acid, to form the corresponding ester. This reaction may be illustrated in the following manner:

The final step of the method consists in reacting the ester so obtained with pyridine, or one of its homologues, as subsequently specified. Such reaction may be indicated inthe following man- As suggested, one may not only use pyridine, but other homologues of pyridine, that is, members of the pyridine series. For instance, members of the pyridine series suitable as reactants include pyridine, alkylated derivatives of pyridine, particularly alkylated derivatives, in which the alkyl radical contains three carbon atoms, or less, and especially methylated pyridine, i. e., pyridines in which one, two or three methyl groups have been substituted in the nucleus, such as picolines, lutidines and collidines. Also suitable as reactants, are the comparable quinolines and isoquinolines, along with C-methyl homologues thereof. Coal tar bases represent mixtures of suitable heterocyclic materials which may be used as such, or after suitable purification, without separation into the individual components.

While chloroacetic acid or chloracetyl chloride is the preferred halogen carboxylic acid compound, other halogen acids, halogen substituted acyl halides, and esterifying derivatives are suitable, particularly a-halogen carboxylic acids of not over six carbon atoms. When the halogen is in the a-position to the CO group, the reaction seems to go with greater readiness. With the shorter chain esterifying halogen carboxylic acids or their functional equivalents, especially chloracetyl chloride, the reaction goes with great ease. Other halogen acylating compounds which are suitable are, for example, a-chlorpropionic acid, etc, but especially, any acid of the formula:

where R is a hydrogen atom or a methyl, ethyl or butyl radical.

Treatment of water-insoluble phenols with alkylene oxides of the kind enumerated, and particularly, with ethylene oxide, propylene oxide and butylene oxide, is a well known procedure. Such compounds are frequently oxyethylated so as to render them water-soluble. In the present instance, instead of treating one mole of the selected phenol with a large ratio of oxyalkylating agent, one employs instead a comparatively low ratio, as indicated by the value for the letter 12 in prior formulae. In other Words, one treats the phenol with one mole, two moles or three moles of the oxyalkylating agent. The product so obtained is still distinctly water-insoluble, and this is also true of the ester derived therefrom. It is to be noted, however, that such water-insoluble product represents the initial oxyalkylation step in the same type of procedure employed to produce a water-soluble product. Thus, as an example of various patents which teach the oxyalkylation of water-insoluble phenols, including 1 the stepwise addition of the oxyalkylating agent,

attention is directed to the following: British Patent No. 470,181, British Patent No. 452,866, U. S. Patent No. 2,243,330, dated May 27, 1941, to De Groote & Keiser, and U. S. Patent No. 2,233,381, dated February 25, 1941, to De Groote & Keiser.

Having obtained the water-insoluble bis(phenoxyalkanol) methane, such product is esterified with chloracetyl chloride, chloracetic acid, bromoacetic acid, alpha-chloropropionic acid, a1- pha-chlorobutyric acid, or the like. Such reaction, particularly between the acid itself, as differentiated from the acyl chloride, is simply an esterification reaction with the elimination of water, and is preferably carried out in the presence of an inert solvent insoluble in water, which serves to remove the water of formation. Such procedure i -illustrated by numerous patents, including the following: British Patent No. 500,765, U. S. Patent No. 1,732,392, dated October 22, 1929, to Wietzel, and U. S. Patent No. 2,264,759, dated December 2, 1941, to Jones.

Having obtained the diol monoester, it is only necessary to react such compound with pyridine or a pyridine homolog. This reaction takes place rapidly by refluxing in presence of an exces of pyridine, and subsequently removing the excess of pyridine which does not enter the reaction by distillation, and preferably, vacuum distillation. The herein described procedures are illustrated by the following examples:

DI(HYnRoxYALKYLoxYPI-IENYL) METHANE Example 1 One pound mole of the product described under the heading Phenol aldehyde condensation, Example 1 is treated with 2 pound moles of ethylene oxide in presence of one-half of 1% of sodium methylate; as the reaction proceeds, the sodium methylate either dissolves, or is converted into a soluble compound by chemical combination. Reaction is conducted at approximately 125 C. and 100-200 pound gauge pressure for approximately 2 /2 to 4 hours until the reaction appears to be complete, as indicated by the pressure dropping to zero. The product so obtained may be indicated by the following formula:

DI (HYDROXYALKYLOXYPHENYL) METHANE Example 2 The same procedure is employed as in the preceding example, except that 4 pound moles of ethylene oxide are employed instead of 2 pound moles and the period of reaction is approximately fifty percent longer.

DI(IIYnRoxYALKYLoxYPHENYL) METHANE Example 3 The same procedure is employed as in Example 1, preceding, except that 6 pound moles of ethylene oxide are employed instead of 2 pound moles, and the time of reaction is approximately twice that indicated in Example 1. 1

DI(HYDRoxYALxYLoxYPI-IENYL) METHANE Example 4 The same procedure is employed as in the three preceding examples, except that the propylated compound described under the heading Phenol aldehyde condensation, Example 2 is substituted for the amylated derivative employed in the three preceding examples.

DI(HYDROXYALKYLOXYPHENYL) METHANE Example 5 The same procedure is employed as in Examples 1 to 4, preceding, except that propylene oxide is substituted for ethylene oxide.

Previous reference has been made to the fact that the esterification step is carried out in the conventional manner, preferably in the presence of an inert solvent. This simply means that the reactants, to wit, the acid, such as chloroacetic acid, and the phenoxyalkanol, are mixed in equimolar proportions, in presence of a solvent in which both are soluble, such as xylene, cymene, decalin, or the like, The mixture is refluxed at some suitable temperature, above C. and below 200 C., so that water of formation resulting from the esterification reaction is carried over as a constant boiling mixture. Such mixed vapor is condensed in the customary manner so the water is trapped off, measured, and then discarded and the solvent returned to the reaction vessel for further use. Ordinarily, such reactions are catalyzed by the addition of an acidic catalyst, such as toluene sulfonic acid, a oresyl phosphoric acid, dry hydrochloric acid, trichloroacetic acid, or the like. Insofar that the alpha-chlorocarboxy acids show marked acidity in comparison with the unchlorinated carbox acids, the reaction may be conducted without an added catalyst, if desired, or in the presence of an added catalyst, such as /2% to 1% of toluene sulfonic acid. Such catalyst tends to discolor the final product, but this is often immaterial, as, for example, when the product is used as a demulsifier. The entire procedure is too well known to require further elaboration, but is illustrated by the following v examples ESTER Example 1 ESTER Example 2 The same procedure is followed as in the preceding example, except that the Di(hydroxyalkyloxyphenyhmethanes prepared as described under the headings of Examples 2, 3, 4 and 5, are substituted for the compound employed in the previous example.

ESTER Example 3 The same procedure is employed as in the two preceding examples, except that a-chloropropionic acid is substituted for a-chloroacetic acid.

Esme

Example 4 Chloroacetylchloride is substituted for chloroacetic acid. The reaction starts to take place rapidly between 45 C. and 80 C. and the temperature should be controlled so the reaction takes place at the lowest suitable temperature. The acylchloride should be added slowly to the di(hydroxyalkyloxyphenyl)methane with constant and vigorous stirring, Hydrochloric acid is formed and should be vented and disposed of in a suitable manner. If the reaction does not take place promptly, the temperature should be raised moderately, for instance, to (1,01 a bit higher, until the reaction proceeds smoothly. However, as soon as the reactiondoes start, the temperature should be lowered until the reaction proceeds at the slowest feasible rate. Generally, this means use of proper cooling devices or controlled slow addition of the a'cyl chloride. Completeness of the reaction" can be determined in any suitable manner, such as a check on the amount of hydrochloric acid eliminated, or the drop in nydroxyl' value of the reactant mixture. When the reaction is complete, any hydrochloric acid gas dissolved in the reaction mass should be eliminated by passing an inert gas, such as carbon dioxide, through the'mixture.

In the prdfiillg fiibddlli's the ester was obtallled b'yi reactinga single mole of a di(hy ilroxya1ky1oxyphenyhmetnane with one mole of ch10- roacetic acid, or its equivalent. Actually, instead of using a di'(hydroxyalkyloxyphenyl)methane, as previousl described, one could have employed instead a hyaroxyaikyioxyphenyi phenylol methane. To producesuch a product, all that is required is to treatthe' phenol aldehyde condensertion, as previously prepared, with one mole of an oxy'alky-lating agent instead of 2 moles. This is illustrated by the following examples HYpRoxYALxYLoxYPHENYr; PHENYLOL METHANE Example 1 tai'r'ied may indicated by the following formule:

person on Amyl -Amyl HYDROXYALKYLOXYPHEN'YL PHENYLOL METHANE Example 2 The same procedure is employed as in the imniefdiately preceding Example Lexcept that propylene oxide is employed instead of ethylene oxide.

HYDROXYALKYLOXYPHENYL PHENYLQL METHANE Example 3 The same procedure is employed as in Example 1, except that butylene oxide is employed instead of ethylene oxide.

HYnRoxYALKYtoxYPHeNYr; PHENYLOL MsrHANE Example 4 The same procedure is employed as in the three preceding examples, except that the propylated compound described under the heading "Phen01 aldehyde condensation, Example 2 is substituted for the amylated derivative employed in the thr'ee'preceding examples.

Having obtained such monohydrio alcohol instead of a diol, este'riiicatio'n issubstantially the same as if a diol were employed, insofar that the proportion of reactants is still mole for mole. This is illustrated briefly in the following man'- ner:

ESTER Example 5 One pound mole, of the compound described under the heading Hydroxyalkyloxyphenyl phenylol methane, Example 1, preceding, is mixed with 1 pound mole of chloroacetic acid and the mixture refluxed with an appropriate trap for I removal of 1 pound mole of water, at a temperature of approximately 155 to 225 C. The time required is usuallyS to lOhours. The resultant is a dark colored viscousliquid.

ESTER Example 6 The same procedure is followed as in preceding Example 5,- except that hydroxyalkyloxyphenyl phenylol methane, as described under the headings of Examples 2, 3 and 4, is substituted for the compound employed in the previous Example 5. I

Estes Example 7 The same procedure is followed as in the two preoedingExamples 5 and 6, except that a-chloropropionic acidis substituted-for a-chloroacetic' acetic' acid. The reaction starts to take place 1 rapidly between'C. and C. and the temperature should be controlledso that the reaction takes place at the lowest suitable temperature. The acylchloride should be added slowly to the dihydroxyalkyloxyphenyl methane with consta-nt and vigorous stirring; Hydrochloric acid is formed and should be vented and disposed of in a suitable manner. If the reaction does not take place promptly, the temperature should be raised moderately, for instance, to 15 C., or a bit higher, until the reaction proceeds smoothly. However, as soon as the reaction does start, the temperature should be lowered until the reaction proceeds at the slowest feasible rate. Generally, this means use of proper cooling devices or controlled slow addition of the acyl chloride. Completeness of the reaction can be determined in any suitable manner, such as a check on the amount of hydrochloric acid eliminated, or the drop in hydroxyl value of the reactant mixture. When the reaction is complete, any hydrochloric acid gas dissolved in the reaction mass should be eliminated by passing an inert gas, such as carbon dioxide, through the mixture.

Earlier reference was made to the fact that the diol might be esterified mole for mole with a low molal monocarboxy acid or its eqiuvalent, such as the acyl chloride having 7 carbon atoms or less. Such procedure may be illustrated in the following manner:

ACYLATED DI(HYDROXYALKYLOXYPHENYL) METHANE Example 1 One pound mole of the material described under the heading Di(hydroxyalkyloxyphenyl) methane, Example 1, is reacted with one pound mole of acetic acid so as to produce a fractional ACYLATED DI(HYDROXYALKYLOXYPHENYL) METHANE Example 2 The same procedure is employed as in immediately preceding Example 1, except that the substituted methanes described under the heading Di (hydroxyalkyloxyphenyl) methane, Examples 2 to 5, are substituted for the material-employed in the said preceding Example 1.

ACYLA'I'ED D'I(HYDROXYALKYLOXYPHENYL) METHANE Example 3 The same procedure is employed as in the previous examples, except that acetic acid is replaced with propionic acid or butyric acid.

Acylated derivatives of the kind described immediately preceding, may be subjected to further oxyethylation so as to introduce 1, 2, 3 or more alkylene oxide radicals. The result of such procedure results in unsymmetrical oxyalkylation, in the sense that the compound is not symmetrical in respect to the distribution of the alkylene oxide radicals. Such derivatives can be subjected to reaction with chloroacetic acid, or similar reactants, in the same manner as the acylated di- (hydroxyalkyloxypheny'l) methane, previously de- 12 scribed. The last mentioned esters are illustrated in the following manner:

required is usually 3 to 10 hours. The resultant is a dark colored viscous liquid.

ESTER Example 10 The same procedure is followed as in the preceding examples, except that acylated di(hydroxyalkyloxyphenyDmethane prepared as described under the headings Acylated di(hydroxyalkoxyphenyl) methane, Examples 2 and 3, preceding, is substituted for the compound employed in the previous example.

ESTER Example 11 The same procedure is employed as in the two preceding examples, except that a-chloropropionic acid is substituted for a-chloroacetic acid.

ESTER Example 12 Chloroacetylchloride is substituted for chloroacetic acid. The reaction starts to take place rapidly between 45 C. and C., and the temperature should be controlled so that the reaction takes place at the lowest suitable temperature. The acylchloride should be added slowly to the a c yl a t e d di hydroxyalkyloxyphenyl) methane with constant and vigorous stirring. Hydrochloric acid is formed and should be vented and disposed of in a suitable manner. If the reaction does not take place promptly, the temperature should be raised moderately, for instance, 5 to 15 C., or a bit higher, until the reaction proceeds smoothly. However, as soon as the reaction does start, the temperature should be lowered until the reaction proceeds at the slowest feasible rate. Generally, this means use of proper cooling devices, or controlled slow addition of the acyl chloride. Completeness of the reaction can be determined in any suitable manner, such as a check on the amount of hydrochloric acid eliminated, or the drop in hydroxyl value of the reactant mixture. When the reaction is complete, any hydrochloric acid gas dissolved in the reaction mass should be eliminated by passing an inert gas, such as carbon dioxide, through the mixture.

Having obtained an ester of the kind exemplified by the previous examples, or the bromo derivative, instead of the chloro derivatives, the next step simply involves reaction with pyridine, or a pyridine homolog of the kind previously described. The reaction takes place fairly rapidly, and usually, is complete within 4 to 20 hours, particularly if an excess of pyridine is employed. The esters previously described are invariably viscous or semi-solid masses which are soluble in pyridine without difiiculty,

3' P mmm H iti Example 1 One pound mole of the ester described in Example 1, preceding, is refluxed with constant stirring with several pound moles, for example, four to six, of technically pure pyridine. The reaction is conducted from approximately 4 to 20 hours at a temperature in excess of 115 0., or thereahouts, until reaction is complete. Completeness of the reaction can be determined by distilling the uncombined pyridine from a sample and noting by difference percentage of pyridine which has been combined. Another suitable test is the deternnfation of ionizable halogen, for

Chlorine 1/H2C.C O OHlCgO ,-N

OCzHlOH Amylm PYRIDINIUM HALIIJE Example 2 The same procedure is followed as in Example 1, preceding, except an ester exemplified by Ester, Example 2 and Ester, Example 3, preceding, is substituted for the ester employed in the preceding Example 1.

PYRIDINIUM HALIDE Example 3 The same procedure is followed as in the two immediately preceding examples, but instead of using technically pure pyridine, one employs a commercial pyridine in which there is present some monomethylpyridine and dimethylpyridine in addition to unsubstituted pyridine.

Pynrnnmnvr HALIDE Example 4 The same procedure is followed as in Pyridinium halide, Example 1, preceding, except that the compound subjected to reaction with pyridine is a hydroxyalkyloxyphenyl phenylol methane derivative as described under the heading Hydroxyalkyloxyphenyl phenylol methane, Example 1" and converted into an ester in the manner described under the heading Ester, Example 5. The compound so obtained is indicated by the following structure:

PYRIDINIUM HALIDE Example 5 The same procedure is followed as in preceding Pyridinium halide, Example 4, except that instead of using Ester, Example 5, as a reactant, one employs instead Ester, Example 6 or Ester, Example 7.

PYRIDINIUM HALIDE Ezcample 6 The same procedure is followed as in Pyridinium halide, Examples 4-. and 5, immediately preceding, but instead of using technically pure pyridine, one employee commercial pyridine in which there is present some monoethylpyridine and dimethylpyridine in addition to unsubstituted pyridine PYRIDINIUM HALIDE Example 7 The same procedure is followed as in Pyridinium halide, Example 1 or Pyridinium halide, Example 4, except that the reactant is a compound derivedrrom an acylated di(hydroxyalkyloxyphenyDmethane, which has been converted into an ester, as exemplified by Ester, Example 9. The compound so obtained has the following structure:

Chlorine PYRIDINIUM I'IALIDE Example 8 The same procedure is followed as in Example '7, preceding, except that one employs instead, ester of Example 9, Example 10, or Example 11.

PYRIDINIUM HALIDE Example 9 The same procedure is followed as in the two examples immediately preceding, but instead of using technically pure pyridine, one employs a commercial pyridine in which there is present some monoethylpyridine and dimethylpyridine in addition to unsubstituted pyridine.

PYRIDINTUM HALIDE Example 10 The same procedure is followed as in the three examples immediately preceding, except that one employs reactants involving unsymmetrical oxyethylation or unsymmetrical alkylation, as described in the paragraph immediately following the heading Acylated di(hydroxyalkyloxyphenyl) methane, Example 3.

It is to be emphasized that all of the products herein contemplated are water-dispersible, or at least, produce a colloidal sol after reaction with pyridine or pyridine homolog. The reactants, prior to such procedure, are not water-soluble. The compounds contemplated vary from fairly viscous liquids to semi-solids and solids. When produced in either glass or iron vessels, they invariably have a dark amber color.

In summary then, the herein contemplated 15' compounds may be indicated by the following structural formula:

in which R20 is an alkylene oxide radical containing at least 2 and not more than 4 carbon atoms selected from the class consisting of ethylene oxide, propylene oxide, butylene oxide, glycide and methylglycide radicals; n is a small whole number varying from 1 to 3; OC.R3 is the acyl radical of a low methyl monocarboxy acid having not more than 6 carbon atoms in which an alpha-hydrogen atom has been removed; NR4 represents a radical of a heterocyclic compound of the pyridine series selected from the group consisting of pyridine, quino1ine,isoquinoline, and C-linked methyl homologues; R is a low molal aldehydic residue having not over 7 carbon atoms selected from the class consisting of methylene and substituted methylene radicals; R6 is a member of the class consisting of hydrogen atoms and alkyl radicals having not over 8 atoms and with the additional proviso that the phenolic residues are substituted monocyclic phenol radicals having two of the three reactive 2, 4, 6 positions substituted by two alkyl side chains, of which at least one contains three carbon atoms, and the longest of which does not contain more than 8 carbon atoms; R9 is selected from the class consisting of hydrogen atoms, (R20)nH radicals and (R20)n.OCR8 radicals, in which R20 and n have their prior significance and RsCO is the acyl radical of a monocarboxy acid having 7 carbon atoms or less.

The new materials or compositions herein described form the subject-matter of our co-pending divisional application Serial No. 630,978, filed November 25, 1945.

Conventional demulsifying agents employed in the treatment of oil field emulsions are used as such, or after dilution with any suitable solvent, such as water; petroleum hydrocarbons, such as gasoline, kerosene, stove oil; a coal tar product, such as benzene, toluene, xylene, tar acid oil, cresol, anthracene oil, etc. Alcohols, particularly aliphatic alcohols, such as methyl alcohol, ethyl alcohol, denatured alcohol, propyl alcohol, butyl alcohol, hexyl alcohol, octyl alcohol, etc., may be employed as diluents. Miscellaneous solvents such as pine oil, carbon tetrachloride, sulfur dioxide extract obtained in the refining of petroleum, etc., may be employed as diluents. Similarly, the material or materials employed as the demulsifying agent of our herein described process for resolving petroleum emulsions may be admixed with one or more of the solvents customarily used in connection with conventional demulsifying agents. Moreover, said material or materials may be used alone, or in admixture with other suitable well known classes of demulsifying agents.

It is well known that conventional demulsifying agents may be used in a water-soluble form, or in an oil-soluble form, or in a form exhibiting both oil and water solubility. Sometimes they may be used in a form which exhibits relatively limited oil solubility. However, since such reagents are sometimes used in a ratio of 1 to 10,000, or 1 to 20,000 or even 1 to 30,000, or even 1 to 40,000, or 1 to 50,000, in desalting practice, such as apparent insolubility in oil and water, is not significant, because said reagents undoubted- Methyl alcohol 1y have solubility within the concentration employed. 'This same fact is true in regard to the material or materials employed as the demulsifying agent of our process.

We desire to point out that the superiority of the reagent or demulsifying agent contemplated in our process is based upon its ability to treat certain emulsions more advantageously and at a somewhat lower cost than is possible with other available demulsifiers, or conventional mixtures thereof. It is believed that the particular demulsifying agent or treating agent herein described will find comparatively limited application, so far as the majority of oil field emulsions are concerned; but we have found that such a demulsifying agent has commercial value, as it will economically break or resolve oil field emulsions in a number of cases which cannot be treated as easily or at so low a cost with the demulsifying agents heretofore available.

In practising our process for resolving petroleum emulsions of the water-in-oil type, a treating agent or demulsifying agent of the kind above described is brought into contact with or caused to act upon the emulsion to be treated, in any of the various ways or by any of the various apparatus now generally used to resolve or break petroleum emulsions with a chemical reagent, the above procedure being used either alone or in combination with other demulsifying procedure, such as the electrical dehydration process.

The demulsifier herein contemplated may be employed in connection with what is commonly known as down-the-hole procedure, i. e., bringing the demulsifier in contact with the fluids of the well at the bottom of the well, or at some point prior to the emergence of said fluids. This particular type of application is decidedly feasible when the demulsifier is used in connection with acidification of calcareous oil-bearing strata, especially if suspended in or dissolved in the acid employed for acidification.

A somewhat analogous use of our demulsifying agent is the removal of a residual mud sheath which remains after drilling a well by the rotary method. Sometimes the drilling mud contains added calcium carbonate or the like to render the mud susceptible to reaction with hydrochloric acid or the like, and thus expedite its removal.

One preferred and more narrow aspect of our invention, insofar as it is concerned with demulsification of petroleum emulsions of the water-inoil type, is concerned with the admixture of the aminoester, as described, with a viscosity-reducing solvent such as the various solvents enumerated, particularly aromatic solvents, alcohols, ether alcohols, etc., as previously specified. The word solvent is used in this sense to refer to the mixture, if more than one solvent is employed, and generally speaking, it is our preference to employ the demulsifier in a form representing 40% to demulsifier and 15% to 60% solvent, largely, if not entirely, non-aqueous and so selected to give a solution or mixture particularly adaptable for proportional pumps or other measuring devices. The following examples will illustrate this aspect of our invention:

DEMU'LSIFIER Example 1 ,Per cent Pyridine halide, Example 1 60 Xylene 30 10 DEMULSIFIER Example 2 Per cent Pyridinium halide, Example 4 65 Commercial cresol 25 Isopropyl alcohol 10 DEMULSIFIER Example 3 Per cent Pyridinium halide, Example 7 55 Decalin 10 Cymene l Dichloroethyl ether 25 The above percentages are by weight.

In many instances, the materials obtained, rather than being characterized as a viscous semi-solid, probably should be referred to as tacky sub-resin or tacky resin. The aldehyde condensate, particularly when derived from formaldehyde, shows not only viscosity, but tackiness approaching or actually in the stringy state. This particular property is usually enhanced after conversion into a pyridinium compound. This enhancement applies usually to both the stringy character and the resinous character. Such change appears to be imparted by the fact that the large molecular structure still exists, but in addition, an ionic structure has been superimposed on the somewhat unusual molecular structure. This ionic structure naturally acts the same as such structure would act in an ordinary inorganic salt crystal. One result of such peculiarity is, that sometimes water solubility may be obsoured. For instance, tests have been indicated previously which are employed to show when the reaction with pyridine has gone to completion. On completion, the structure of the resultant may be so resinous and so tacky, that it shows a very slow rate of solubility in water. Thus, a test may at first sight indicate the product is still water-insoluble, whereas, it is actually water-soluble, or at least, seli-emulsifiable. To guard against such possible error, it is well to take a small amount of the reaction mass and reflux it with an excess of water, or better still, dissolve the reaction mass by warming in methyl alcohol and then dilute with an excess of water.

This same feature merits consideration in the manufacture of the foregoing demulsifiers. If the demulsifying mixture, as amplified by Examples 1, 2 and 3, preceding, does not fOrm a homogeneous mixture, in combination with the indicated solvents, then methyl alcohol should be added until a homogeneous mixture is obtained. Sometimes a mixture of 50% water and 50% methyl alcohol is even better. The basic principle involved is that these products are polar or ionic and their solution is accelerated by the presence of a polar solvent.

Oddly enough, however, in light of the enormous hydrophobe radical present in their structure, their solution may also be accelerated by a comparatively non-polar solvent, such as kerosene, or a semi-polar solvent, such as cresylic acid.

Polar solvents yield both dilute and concentrated solutions, sols or homogeneous mixtures, whereas non-polar and semi-polar solvents may only yield comparatively concentrated solutions or sols in some instances.

Attention is directed to our co-pending appli 18 cations for patent Serial Nos. 630,973, 630,974, 630,977 and 630,978, filed November 26, 1945.

Having thus described our invention, what we claim as new and desire to secure by Letters Patcut is:

1. A process for breaking petroleum emulsions of the water-in-oil type, characterized by subjecting the emulsion to the action of a demulsifier comprising a hydrophile compound of the formula:

in which R20 is an alkylene oxid radical containing at least 2 and not more than 4 carbon atoms selected from the class consisting of ethylene oxide, propylene oxide, butylene oxide, glycide and methylglycide radicals; n is a small whole number varying from 1 to 6; R3.CO is the acyl radical of a low methyl monocarboxy acid having not more than 6 carbon atoms in which an alpha-hydrogen atom has been removed; NERA represents a radical of a heterocyclic compound of the pyridine series selected from the group consisting of pyridine, quinoline, isoquinoline, and C-linked methyl homologs; R5 is a low molal aldehydic residue having not over 7 carbon atoms selected from the class consisting of methylene and substituted methylene radicals; R6 is a member of the class consisting of hydrogen atoms and alkyl radicals having not over 8 atoms and with the additional proviso that the phenolic residues are substituted monocyclic phenol radicals having two of the three reactive, 2, 4, 6 positions substituted by two alkyl side chains, of which at least one contains three carbon atoms and the longest of which does not contain more than 8 carbon atoms; R9 is selected from the class consisting of hydrogen atoms, (R20) 11H radicals and (RzOMDCRs radicals, in which R20 and n have their prior significance and RaCO is the acyl radical of a monocarboxy acid having not over 7 carbon atoms.

2. The process of claim 1, wherein the halogen is chlorine.

3. The process of claim 1, wherein the halogen is chlorine, and n is one.

4. The process of claim 1, wherein the halogen is chlorine, n is one, and the alkylene oxide radical is the ethylene oxide radical.

5. The process of claim 1, wherein the halogen is chlorine, n is one, the alkylene oxide radical is the ethylene oxide radical, and all alkyl radicals are amyl radicals.

MELVIN DE GROOTE.

BERNHARD KEISER.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,990,985 Fonrobert et al. Feb. 12, 1935 2,255,252 Harris Sept. 9, 1941 2,299,756 Katzman et al Oct. 27, 1942 2,306,775 Blair Dec. 29, 1942 2,331,265 Coleman et al. Oct. 5, 1943 2,372,257 De Groote et al. Mar. 27, 1945 2,385,975 De Groote et al. Oct. 2, 194-5 

